Device for producing pizza

ABSTRACT

The invention is an apparatus for producing pizza by a mechanical, automated system without using baking tins for the dough bases and without using pre-prepared or pre-shaped bases. Dough bases are individually prepared from fresh pre-proportioned dough ingredients by a kneading and extrusion device. The dough base is then passed through a series of processing stations, such as a shaping press, a metering and distribution device for tomato purees or sauces, at least one metering and distribution station for garnishing (topping) ingredients and a baking station. The dough bases pass through the series of stations on a preheated or continuously heated transportation sheet. No pre-produced or pre-cooked, semi-finished products are used in the method. Each dough base is prepared and provided with toppings according to individual orders selected from a list.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional of application Ser. No. 09/294,702,filed Apr. 19, 1999, now U.S. Pat. No. 6,245,370 which application isincorporated in its entirety by this reference.

This application is a continuation-in-part application of anotherinternational application filed under the Patent Cooperation Treaty onAug. 12, 1998, bearing Application No. PCT/EP98/05093, and listing theUnited States as a designated and/or elected country. The entiredisclosure of this latter application, including the drawings thereof,is hereby incorporated in this application as if fully set forth herein.

BACKGROUND OF THE INVENTION Field of the Invention

The present invention relates to a method and the correspondingapparatus for the mechanized and automatic production of ready-to-eatpizza, flat cakes, and the like, starting from fresh ingredients byindividual production based on individual single orders.

Methods and apparatuses are known for the automatic industrialproduction-line and mass-produced production of pizzas and flat cakes,which essentially comprise the following work phases: preparation of thedough including rising of the dough, extruding the dough for the purposeof forming a connected mass, cutting a dough strand into the doughportions, processing the dough portions to flat round cakes, addingseasonings and toppings, baking, packaging for a consumption within theexpiration date or, respectively, for deep freezing. The apparatuses forperforming this method are voluminous and require much space,furthermore, several conveyor belts are required in order to transportthe product from one device to the next. In order to accelerate theproduction of the dough, some methods employ a pre-treated, driedgranulate, the seasoning, topping, and/or stuffing is carried out on aminimum number of pizzas of the same kind and in fact during the passageof the pizzas, which are disposed at small distances relative to eachother on the conveyor belt and are subsequently baked in a tunnel oven;some methods bake the pizza in its own baking tins in order to allow theplacement and sliding into the baking oven.

The technical features of these known devices do not allow individualproduction of pizzas according to individual single orders based on aselection from a list.

In addition, installations are known, wherein the pancakes are presentin a pre-produced and possibly precooked kind and are taken from thefreezer garnished and baked or, respectively, heated up.

SUMMARY OF THE INVENTION

1. Purposes of the Invention

It is an object of the present invention to furnish a method and acorresponding device for mechanical and automatic production of pizzas,ordered individually based on an individual selection from a list, andin fact starting from non-pre-cooked and/or non-deep-frozen ingredientsfor the dough, which pizzas are individually seasoned, spiced,garnished, stuffed and baked and are available ready for consumptionwithin a short time.

It is another object of the invention to furnish the method and theapparatus such that the production process is performed hygienically andwithout human intervention and where periodic and automated washing andsterilization cycles. are provided for the purpose of maintaining theplant and in particular with reference to the hygiene and thecleanliness of the plant.

It is yet a further object of the invention to furnish periodically andin a simple fashion exchangeable parts, where these parts are coming incontact with foodstuffs and where these parts are not already subjectedto the germicidal effect of an elevated temperature.

It is still a further object according to the present invention toconstruct such an installation for the perishable food components of thepizza and for the emptied packaging material as to allow for astockkeeping which is appropriate for foodstuffs.

These and other objects and advantages of the present invention willbecome evident from the description which follows.

2. Brief Description of the Invention

The present invention provides a linear or circular production line forachieving these objects, comprising the following devices:

a conventional mixer including a charge device for the flour mixture or,respectively, a metering device which empties

already pre-mixed and pre-proportioned amounts or partial amounts of thedough ingredients into the kneading device;

a conventional metering and weighing device;

a novel kneading and extrusion device;

a novel shaping and molding device for the flat cake;

a novel device for metering tomato pulp with a tomato pulp distributor;

several novel metering and distribution devices;

a novel insertion device for the baking oven;

a novel baking oven;

a novel discharge and removal device for the baked pizza and

a transport device for the flat cake from its shaping stage to thebaking oven.

The invention does not exclude that one or several of the above-recitednovel devices are replaced by one or several corresponding conventionaldevices. The kneading and extrusion device is an essential component ofthe method. Two transport and kneading worms, operating perpendicular toeach other, allow the kneading and extrusion device to realize aneffective mixing of the dough components (flour, salt, sugar, yeast,water, etc.), a homogenization, an interspersing, a densification, andfinally the extrusion with the discharge of the portion amount based onan independently controllable rotational speed of the two worms relativeto each other. The core piece of this kneading and extrusion device isthe transition region from the first worm to the second worm, whereinthe second worm disposed perpendicular to the first worm. The dough massis subjected in this region to a torsion motion with repeated.shearingby the worm wall, which effects an intensive interspersing underformation of air bubbles and homogenization, which equals an intensiveand continuous kneading through of the mass and is decisive for auniform shaping and baking through of the flat cake or pizza. Thearrangement according to the present invention of the worms, theirconstruction form and the tuning of the worm casing allow in a shorttime to extrude a professionally prepared portion of dough. Theapparatus is cleanly flushed and sterilized with hot air according to apre-programmed washing and sterilization cycle through an increase ofthe rotation speed and change of the rotation direction of the worms. Acompact dough portion is extruded in case of a proper metering of theingredients of the dough mixture and upon an exact tuning of therotation speeds of the two worms. The dough portion is separated at thedischarge of the casing, possibly by way of a cutting device, and fallsonto the transport plate readied under the casing discharge. A closureplate at the input of the casing and the possible cutting device at thedischarge of the casing or at the extrusion nozzle close the kneadingdevice during the standstill of the worms. The transport plate accordingto the present invention can be produced of different materials and ispreferably heated or preheated by electrical thermal resistors so thatthe dough, or, respectively, the flat cake does not stick to thetransport plate and becomes pre-heated during the following work phasesin order to obtain thereby the required rigidity in order to not todeform during placement into the baking oven and in order to shorten thebaking time.

According to the present invention, the transport plate simultaneouslyserves as a dough support during the shaping of the flat cake or flatdough base and as a support at the oven entrance during the sliding andplacement of the flat cake into the baking oven. It is, however, notexcluded that the transport plate is a relatively thin metal sheet,which metal sheet rests on a transport support and is placed togetherwith the flat cake into the baking oven.

The shaping of the flat cake according to the present invention isperformed under a press which flattens the dough portion to apredetermined thickness by lowering a horizontal disk against thetransport plate disposed below the horizontal disk. The lowerable heateddisk is furnished with a ring which is supported horizontally shiftableat a distance to the circular disk's outer edge when subjected to aspring interaction. This ring furnishes a circular form to the outeredge of the flat cake by forming a bead in the intermediate spacebetween the extruder's outer edge and the inner side of the ring duringthe stamping procedure from the dough squeezed out laterally frombetween the transport plate and the extruder plate. Initially, the ringrests at the surface of the transport plate during the stampingprocedure. Then, based on a further lowering of the press plate, thedough portion is flattened to a flat cake or flat dough base. Thesprings between the support of the ring and the ring are compressedduring this phase. Then the press plate is lifted up again, the springscan thereby be relaxed again. This bead forms at the same time a barrierin order to prevent during the following a distribution of tomato pulp,sauces or purees. The formation of the flat cake with the describedapparatus is time-saving and allows always to form a uniform round flatcake with a thicker upwardly projecting edge region even in case of asomewhat different dough portion; simultaneously, it is prevented withthe heated transport plate and press plate that the dough sticks to theplate surfaces and achieves a pre-heating of the flat cake.

The transport plate including the formed flat cake is furthertransported after the shaping of the flat cake under the metering andthe distribution device for tomato pulp, sauces or purees. This meteringis performed with a peristaltic pump and a ring of nozzles such thatseveral product volumes fall dispersed onto the flat cake disposedtherebelow. The distribution of these product volumes is performed withseveral air beams (foodstuff-suitable air), which exit from air nozzlesplaced in the region of the product discharge and which several airbeams are directed onto the product volumes disposed on the flat cake.It is possible to exchange the complete hose through which the productflows for purposes of cleaning by employing a peristaltic pump, wherethe feed line, the discharge line, the pump part and the exit nozzlesform one single tubular piece. The transport plate passes throughseveral metering stations after the metering station for the tomatopulp, the sauces or the puree, which metering stations can be all of thesame kind or of different kinds. The invention teaches in principal twodifferent metering systems, one metering system feeding the garnishingingredients packed in a bubble band, wherein the ingredients are weldedin individual portions in bubbles between two plastic foils, possibly ina controlled atmosphere, and a further metering system, wherein thegarnishing ingredients are packed into small dishes, wherein severaldishes form a stack and wherein in each case the uppermost dish formswith its floor the cover of the dish below; in this case, the stack ofdishes can be packed in a controlled atmosphere. The two packagingsystems according to the present invention allow a hygienicfoodstuff-friendly packaging, a precise portioning, a simple compactstorage within a cooled container in the form of rolls or, respectively,of stacks of dishes, and a controlled waste-free placement onto thesurface of the flat cake. As a rule, each of the metering devices forthe garnishing ingredients is combined with a dispersing device disposedunder the metering devices.

The metering device according to the invention for garnishingingredients in bubble bands includes a mechanical roller device, whereinthe mechanical roller device pulls the bubble band with the welded-inportions from the cooled storage box, and wherein the mechanical rollerdevice pulls apart the two welded foils of the bubble band above thedispersing mechanism, whereby the ingredient portions (finely cut softcheese, ham pieces, vegetable pieces, etc.) fall onto the dispersingdevice and are dispersed by vibration by the dispersing device byfalling through a sieve and/or through a grate onto the flat cakedisposed below the dispersing device. The sieves and/or grates can beeasily exchanged and are made out of a dish-washing-machine-proofmaterial or out of materials which provide for a single use; thisinvention feature allows to maintain hygienic conditions in a simple wayby changing the sieve. The rolled-off foil bands in contrast can runinto their own container or can also run back into the cooled containerof the bubble band.

The metering device for garnishing ingredients packed in stacks ofdishes according to the present invention furnishes that these stacksare entered into cooled magazines and are removed from below by moving aslider past these stacks and wherein these stacks are brought to atilting station for emptying and are then stored as empty dishes. Thealready described dispersion device is in this case also disposed belowthe tilting and discharge station.

The possibility exists that the garnishing ingredients are placed ontothe flat cake in a heap without a dispersing device. Of course, adispersing device can be dispensed with in this case.

It is further to be noted that, depending on the order (according toindividual desire), only specific garnishing ingredients are to beplaced onto the same flat cake or, respectively, that double or threetimes the amount of the same garnishing ingredients is to be disposed;in the latter case, the flat cake will remain under the same meteringstation until the corresponding amount of garnishing ingredients hasbeen dispersed onto the flat cake. This metering system offers tofurnish several magazines for dish stacks with different garnishingingredients, which garnishing ingredients are taken from the same sliderand which all can be dispersed onto the flat cake at the same productionstation. Furthermore, the invention provides that the dishes aresubdivided into cells and are furthermore possibly furnished with a gridor grate, and in this fashion a uniform distribution onto the flat cakecan be achieved already based on the corresponding diameter of the dishand on the disposition of the product in the cells. The contents can bedispersed by vibrating the open and possibly tilted dish in case ofdishes with grid or grate. The baking oven of the installation isconceived for the baking of individual flat cakes. The sliding in of thegarnished flat cake, continuously pre-heated during the individualrecited work phases by the transport plate, can be performed in atraditional mechanical way or by way of the insertion device accordingto the present invention, which insertion device is furnished at thetransport plate itself. The baking oven includes an insertion openingand a removal opening and, according to the invention, the support platefor the flat cake is rear-ventilated at the bottom side in order tofurnish a hot air chamber (hypocausts). The oven itself, the supportplate for the flat cake and also the two swivel doors are made of aporous vapor-permeable ceramics in order to guarantee thereby the uptakeof the baking vapors and the air exchange (breathing) and in order to beable thus to produce a pizza, which equals in taste a pizza baked in acharcoal-fired oven. The baking oven according to the present inventionincludes a corresponding heat tunnel disposed at the sliding-in openingand at the removal opening, whereby it is prevented during the slidingin or, respectively, during the removal that the air exchange isperformed in the baking zone proper with air preheated in these zones bydischarge heat.

The withdrawal device according to the present invention comprises inprinciple an insertable grate or baking sheet which is slid under thebaked flat cake, and which roasting support or a sheet metal piece keepsthe swivel door open during the operational steps when sliding-in basedon an upwardly bent side edge, and wherein the upwardly bent side edgeis higher than the pizza such that the pizza cannot be stripped off fromthe grate or baking sheet. After the actual removal motion, the removalgrate is tilted and the pizza slides to the discharge, where a (one-way)plate or a take-out container stands ready. The passage of the heatedtransport plate from the region below the kneading and extruder stationup to the slide-in opening of the baking oven and back again can forexample be performed by way of a chain, a toothed belt, or a pull chain;also an arrangement of the individual production stations in a circularlayout is not excluded. The invention further does not exclude that thetransport plate is driven all the way into the baking oven and thatpossibly two transport plates are moved with the same drive or withseparate drives and/or that the return path is performed on its ownguides, possibly at the bottom side, whereby it becomes possible that,for example while a flat cake is being garnished, the next flat cake isalready being formed; in this case it can be advantageous to furnish abaking oven with two baking surfaces. There exists however also thepossibility that two garnishing lines charge a single, possibly movable,baking oven with several baking zones separated from each other.

The invention method provides that a cleaning and exchange cycle isfurnished for the purpose of maintaining hygiene, wherein the cleaningand exchange cycle performs an automatic emptying, flushing andsterilization of the kneading device with hot air and requires theexchange of the hoses including nozzles for the tomato pulp as well asof the grate and/or sieves of the dispersing devices.

The invention is in the following explained in detail by way of apreferred exemplified embodiment illustrated schematically in theaccompanying drawings, wherein the embodiment shows an apparatus for theproduction of pizzas operating according to the invention method; inthis context the drawings perform a purely explanatory and not alimiting purpose.

The novel features which are considered as characteristic for theinvention are set forth in the appended claims. The invention itself,however, both as to its construction and its method of operation,together with additional objects and advantages thereof, will be bestunderstood from the following description of specific embodiments whenread in connection with the accompanying drawing.

BRIEF DESCRIPTION OF THE DRAWING

In the accompanying drawing, in which are shown several of the variouspossible embodiments of the present invention:

FIG. 1 shows a schematic diagram with a device according to theinvention for the production of pizzas without illustration of thecooled containers for the individual ingredients and without containersfor the packaging elements produced in a schematic side elevationalview,

FIG. 1a shows a schematic diagram with a device according to theinvention for the production of pizzas similar to the device of FIG. 1,however further illustrating a feeding mechanism employed in doughproduction,

FIG. 2 shows a longitudinal sectional view along a section line whichcontains the two rotation axes of the worms of a kneading and extrusiondevice according to the present invention,

FIG. 2a shows an enlarged side elevational and in part sectional view ofthe feeding mechanism of FIG. 1a,

FIG. 3 shows a schematic sectional view of the shaping device for theflat cakes with the shaping ring according to the present invention,

FIG. 4 shows a functional diagram of the metering and distributionstation for the tomato pulp or the like,

FIG. 5 shows a schematic diagram of a metering device according to theinvention for the garnishing ingredients packed in bubble bandsaccording to the invention and a dispersing device for the garnishingingredients according to the present invention disposed below themetering device,

FIG. 6 shows a schematic diagram with a metering device according to theinvention for the garnishing ingredients packed in dish stacks accordingto the present invention, without a dispersing device disposed beneaththe metering device,

FIG. 6a shows a sectional view of the dispersing and metering devicesuitable in particular for soft cheeze like mozzarella or othergarnishing components sticking together.

FIG. 7 shows a top planar diagramatic view onto a baking oven accordingto the present invention including slide-in device and removal device,

FIG. 8 shows a cross-section according to the section line VIII—VIIIindicated in FIG. 7 through the baking oven according to the presentinvention.

DESCRIPTION OF INVENTION AND PREFERRED EMBODIMENT

The apparatus according to the present invention for the production ofpizzas according to the method of the present invention essentiallyconsists of a base frame 1 (FIG. 1), wherein a conventional mixer 2including a conventional charge device 3 and a conventional metering andweighing device 4 for the dough components is attached to one end of thebase frame 1.

A feeding mechanism for the device performing dough preparation is shownin FIG. 1a in the overall context of the production line and is shown inmore detail in FIG. 2a.

The kneading and extrusion apparatus 5 according to the presentinvention is furnished at the output of this metering and weighingdevice 4, wherein the kneading and extrusion apparatus 5 comprises twoworms 5 a, 5 b (FIG. 2) operating perpendicular to each other withcorresponding casings 5 k, 5 m. The dough components (flour, salt,sugar, yeast, water, etc.) pass in a conventional manner 5 d into thefilling opening 5 c, are captured by the coils 5 e of the first worm andare transported axially into the kneading region, where the worm coil 5e is interrupted and where adjustable mixing blades 5 f are furnished.The casing 5 k passes into a conical part 5 g in the end region of theworm, where the coil of the worm also is again complete and the dough isdensified. The conical part shows an inner diameter reduction to fromabout 0.5 to 0.8 of the inner diameter of the casing 5 k. The dough istransferred from the first worm 5 a to the second worm 5 b in thefollowing region; the rotation speed of the two worms 5 a, 5 b can betuned independently. The dough is subjected to a twisting and a repeatedtorsion by the coil of the second worm 5 h in this transfer region, andan intensive interspersion and air pickup occurs thereby, in thefollowing the dough is further transported to the extruder nozzle 5 iand possibly repeatedly densified at the nozzle 5 i in order to exit 5 jas a compact dough portion 16 and to fall freely onto the transportplate 11 readied therebelow. The invention does not exclude that,instead of a free falling down 5 j of the dough portion, a cuttingdevice at the nozzle 5 i determines this process and that this cuttingdevice, together with a closure device at the input of the housing 5 gcloses the casing upon standstill of the worms.

According to the present invention the transport plate 11 is preferablyelectrically heated, but it is not excluded that the transport plate 11experiences a heating up in the baking oven itself and only in thefollowing assumes the position under the kneading and extrusionapparatus 5. The transport plate is guided on its own guides 1 a at theframe 1 of the installation and is moved back and forth 11 d by way ofchain drive, belt drive, pull train or the like 15 (FIG. 1) between thekneading and extrusion station 5 and the baking oven 13.

As soon as the dough portion 16 rests on the transport plate 11, thetransport plate 11 carries 11 d the dough portion 16 to the shapingdevice 6 (FIG. 3); the shaping device 6 comprises a frame 1 b, whichframe 1 b carries a vertically operating cylinder 6 a, wherein thepiston rod 6 b of the cylinder 6 a supports a holder 6 c, wherein aheated press plate 6 e is attached at the holder 6 c, and wherein acircumferential ring 6 h is supported vertically slidably 6 j under anintermediate action of compression springs 6 g with a pin 6 f at theholder 6 c. Upon lowering 6 i of the press plate 6 e onto the doughportion 16, the dough portion 16 is flattened to a flat cake 16 a of apredetermined thickness. Before the press plate 6 e flattens the dough16, the ring 6 h rests at the transport plate 11, without preventing afurther lowering 6 i of the press plate 6 e, in this context, the pin 6f slides axially in the holder 6 c and the springs 6 g are compressed,the dough flowing out between press plate 6 e and transport plate isaccumulated in the intermediate slot 6 k to a circumferential bead. Thisbead forms a barrier, wherein the barrier prevents that, in particularupon distribution of tomato pulp or other liquid ingredients onto theflat cake 16 a, the tomato pulp or other liquid ingredients flow overthe edge of the flat cake, furthermore this bead forms a larger supportface for the sliding-in mechanism and thus prevents the deformation ofthe flat cake during the sliding-in into the baking oven 13.

The formed flat cake 16 a is carried 11 d further under the tomato-pulpmetering device and distributor 7. This device according to the presentinvention includes a peristaltic pump 7, wherein the feed tube 7 b, thepump tube piece 7 d, and the discharge tube 7 h form an easilyexchangeable unit together with the distributor 7 and the branches 7 iwith the exit nozzles 7 e. The branches 7 i with the exit nozzles 7 eare positioned over the flat cake 16 a such that the tomato pulp isdeposited in specific amounts at several locations uniformly distributedover the surface of the flat cake. The distribution of these amounts isperformed by way of air nozzles 7 g coordinated to each exit nozzle 7 e,and wherein the air nozzles 7 g are fed through a pressure line 7 f withcompressed air suitable for foodstuff production.

All garnishing components, including the tomato puree can be furnishedpreproportioned in dishes or in bubble bands and can be emptied anddelivered above the flat cakes by corresponding mechanisms 8, 9. Inparticular in case of employing a dish with a cellular subdivision, thenno dispersing device is required.

In the following, the flat cake disposed on the transport plate passesthrough 11 d a series of metering devices and dispersing devices 8, 9,or, respectively, 10 for the garnishing ingredients. The methodaccording to the present invention furnishes that the garnishingingredients are stored and processed absolutely hygienically andaccording to the foodstuff regulations. In order to achieve this, thepresent invention furnishes two different metering devices 8 (FIG. 5), 9(FIG. 6); one metering device furnishes that the garnishing ingredients8 b be welded between two foils 8 c, possibly in a controlledatmosphere; the other metering device furnishes that the garnishingingredients 18 a be packed in plastic dishes 18, wherein stacks ofdishes are formed and wherein in each case the cover of the dish isformed by the inserted floor of the next following dish. According to afurther embodiment of the present invention, the individual dishes canhave the required size and possibly round shape and can exhibit cells inorder to be able to dispose the contents already in a uniform shape ontothe flat cake by tilting the dish; this method can also be used for moreliquid garnishing ingredients such as tomato pulp, sauces and purees.According to a further embodiment of the dishes, the dishes can befurnished with a grate or sieve in order to achieve the distribution ofthe topping ingredients by vibrating the dish itself. In the two aboverecited cases, a specific dispersing device 10 is not required and thusthe periodic exchange of the grates or sieves 10 b is also not required.

The dispersing and metering device 8 q shown in FIG. 2a and in detail inFIG. 6a is particularly advantageous for for soft cheeses, formozzarella cheese, for processed cheese or similar sticky garnishingcomponents.

The metering device 8 (FIG. 5) according to the present invention, whichis fed with bubble bands 8 a and wherein the bubble bands 8 a can berolled off from a cooled storage container, comprises a single-sided ortwo-sided feed 8 g. The bubble band 8 a with the welded-in portions 8 bis pulled in by two roller mechanisms 8 f through the single-sided ortwo-sided feed 8 g, and in fact such that each of the roller mechanisms8 f pulls apart 8h one of the foils 8 c which form the band 8 a throughcorresponding rollers 8 e such that the contents 8 b of the bubbles isemptied downwardly 8 d and either falls directly onto the flat cake 16 aor is distributed by a dispersing device 10 according to the presentinvention disposed therebelow onto the flat cake 16 a.

The metering device 9 according to the present invention is fed withstacks of dishes 18 d and provides that these stacks 18 d are stored incooled magazines 9 a after removal of a packaging, possibly sealed in acontrolled atmosphere, wherein the stacks 18 d are taken out of thecooled magazines 9 a with a slider 9 b, wherein the slider 9 b is moved9 c through a piston 9 d and is slid 18 b to a tilting station 17 wherethe contents is emptied and falls downward 18 c while the empty dish 18(one-way dish or reusable dish) is further slid into a storage container17 a for the empty containers.

When employing the dispersing and metering devices 9, wherein thegarnishing ingredients are preproportioned present in dishes, then thesedishes can already be stacked in an inclined position, which allows todispense with a flipping device for the dishes. In this case thecontents of the dish will fall on the pizza or onto a dispersing device10 as soon as the dish is opened.

Of course, in this case as well a known dispersion device or adispersing device 10 according to the present invention can be furnishedunder the emptying station 17 and above the flat cake 16 a.

The dispersion device according to the present invention comprises avibrating holder 10 a, wherein a grate and/or a sieve 10 b can beinserted easily exchangeable into the holder 10 a; these inserts 10 bcan have different forms, they are tuned to the size of the pieces ofthe garnishing ingredients and to the diameter of the flat cake and canbe exchanged in a one-way method or in a multiple-way method in order tomaintain hygienic conditions.

Depending on the order (according to individual desires) also themultiple amount of certain garnishing ingredients can be applied to aflat cake 16 a or also several metering stations 8, 9 can be passedover.

The metering station 9 which is fed with stacks of dishes 18 d issuitable for the purpose that for example several stacks of dishes 18 dcan be furnished with different contents 18 a and that the flat cake 16a is covered with several different garnishing ingredients under asingle one of these metering stations 9. In this case it is requiredthat transport elements are furnished for the individual stacks ofdishes 18 d, which transport elements move or let fall 18 e therespective stack with the desired ingredients with the lowest dish intothe operating region of the slider 9 b. This construction allows tobuild the complete plant in a more compact way and to further shortenthe running-through motion 11 d time of the flat cake 16 a as well asthe production times. Finally the transport plate 11 reaches theinsertion opening 13 a (FIG. 7) of the baking oven 13 after the flatcake 16 a has been garnished according to individual order and the flatcake has in addition also been pre-heated during the work phase on thetransport plate 11. According to the present invention, the transportplate 11 can move into the oven and the pizza is stripped off in thebaking chamber or the transport plate 11 can dwell in the oven 13together with the pizza 16 a during the baking process and can be heatedin the oven 13 and leave the oven 13 only when prompted by the nextorder, or, according to the present invention, an insertion device 11 bcan be constructed on the transport plate 11, which insertion device 11b is placed in insertion position by a cylinder 12, wherein the end ofthe piston rod of the cylinder 12 is furnished with a correspondinglatching device 12 a, wherein the latching device 12 a actuates theinsertion device and slides 11 c the pizza 16 a away 16 b over thetransport plate 11, through the insertion tunnel 13 a, below the openingof the swivel door 13 e, into the baking zone, where the pizza remainslaying. In the following, the insertion device 11 a is again retracted11 c. The opening and reclosing of the swivel door 13 e according to thepresent invention is performed by two pins projecting from the side ofthe transport plate in a forward direction, which pins swivel open theswivel door 13 toward the baking zone 13 c during the approach of thetransport plate 11 to the insertion opening 13 a, and which pins allowthe swivel door to freely swivel closed after the transport plate 11leaves said position. The pulling out 16 c of the baked pizza 16 a canbe performed in a conventional manner, according to the presentinvention the pizza can be removed again with the transport plate 11itself through the insertion opening 13 a, or according to the inventionthe pizza can be removed through a second opening 13 b in line with thefirst opening or staggered, for example by 90 degrees, relative to thefirst, with its own removal device 14. This removal device 14 accordingto the present invention comprises a takeout grate 14 b, slidable 14 dwith a cylinder 14 g at guides 14 a and with upwardly bent side edges,wherein the side edges are higher as compared with the height of thepizza 16 a and which side edges open the swivel door 13 u uponinsertion. The grate 14 b is a slid under the baked pizza 16 a and ispulled out 14 d together with the pizza through the withdrawal tunnel 13b, wherein the swivel door 13 u moves again automatically into a closureposition. In the following, the take-out grate 14 b is swivelledupwardly 14 e over a bearing axle 14 f, whereby the baked pizza slidesoff 16 c and onto a readied dish or onto a take-out container. Theswivel motion of the take-out grate 14 b can, of course, also beperformed sideways.

All parts of the baking oven 13 according to the present invention whichcome into contact with the pizza 16 a and all parts which form thebaking chamber 13 c as well as the insertion tunnel 13 a and the removaltunnel 13 b are breathable, porous ceramic parts. In particular, thesupport 13 d for the pizza 16 a in the baking chamber is ventilatedaccording to the present invention by air chambers (hypocausts) 13 f.This construction allows that the vapors are absorbed continuouslythrough the porous lining elements and the support elements and aredischarged to the outside; practical operation has shown that theseporous materials and the construction according to the present inventionwith a support 13 d ventilated from below, with insertion tunnel andremoval tunnel 13 a, 13 b and the ceramic swivel doors 13 e, 13 u allowto bake a pizza, which equals a traditional charcoal-oven baked pizza intaste. Furthermore, it has been observed that in particular the swiveldoors 13 e, 13 u made of ceramics as well as all remaining ceramic partsare not attacked by chemically aggressive vapors or acid-containingsplashes (tomato pulp). Of course, the swivel doors can also be replacedby vertically guided doors, furthermore, the baking oven can also beconstructed for two or more baking locations disposed next to eachother, in series, or also on top of each other and can be fed byproduction lines disposed parallel to each other, disposed on top ofeach other, or disposed in different directions or in a circle; also,the baking oven can be disposed movable between the production lines.

A further feature of the baking oven according to the invention is thatthe baking chamber is limited closely to the measurement of the goods tobe baked and that the air exchange in the baking zone 13 c is performedby air which is pre-heated in the insertion tunnel 13 a or,respectively, in the removal tunnel 13 b during the insertion or,respectively, during the removal of the flat cake 16 a.

The method according to the present invention and the correspondingdevice allow:

1. The kneading, forming, garnishing, baking and the delivery of pizzato the customer starting from the base components (flour, water,fermenting agent, rising agent, salt, etc.) and the garnishingingredients (tomato puree, mozzarella, ham, mushrooms, etc.) and withouthuman interaction:

a. By completely automatic preparation of the dough within a short timein the apparatus, wherein the base components (flour, water, fermentingagent, rising agent, salt etc.) are automatically portioned or arealready pre-portioned by feeding in the ingredients with a bubble band(8 a) or with dishes (18) united to stacks, wherein a single flourmixture portion is transported into the kneading device or wherein theflour mixture part amounts are entered and transported into the kneadingdevice.

A particularly suitable mechanism to furnish the flour mixture portioninto the kneading device can be recognized from FIG. 2a. This enteringmechanism comprises a casing 5 v which casing 5 v is moved 5 p by anoperating cylinder 5 s working through bolts 5 t at an arm 5 n from areceiving position A (shown in dashed lines) into an entering positionB. The flour mixture falls 5 d in the receiving position A and istransported by a known portioning mechanism from the container 2 a intothe filling chamber 5 w onto the filling piston 5 q. The container 2 aincluding the portioning mechanism can be substituted by a rollermechanism 8 f for the bubble bands 8 a or by a stack of dishes 18 d withemptying mechanism.

After the casing 5 v of the entering mechanisms has been brought 5 p bythe cylinder 5 s into the entering position B, then the piston 5 qincluding the thereupon disposed flour portion is lifted by a cylinder,wherein the flour mixture passes through an opening 5 x to the casing 5k of the kneading device into the operating region of the first worm 5 aand is further transported by the first worm 5 a in axial direction intothe mixing and kneading region. According to the present invention ineach case the quantity for a single flat cake is kneaded and extruded 5j.

b. By forming of a flat cake, wherein the flat cake is pre-baked by thepre-heated, or permanently heated transport plate 11 during the formingand also during the successive processing phases up to sliding into thebaking oven and thereby receives the necessary consistency, whichenables a sliding in 11 c without deformation of the flat cake 16 a andwhich therefore enables the baking directly on the ceramic surface 13 din the baking oven 13.

c. By a presence of all garnishing ingredients pre-portioned in bubblebands 8 a and/or in dishes 18 and by placing with the devices formetering of garnishing ingredients, with or without dispersing mechanism10, onto the flat cake. This holds also for the tomato puree, formozzarella or ham.

Practical experience has shown that the device for metering anddistribution of tomato puree as shown in FIG. 4 can be simplified byhaving a larger number of nozzles in the nozzle ring 7 e in order toobtain thereby a uniform distribution of the product also without airnozzles 7 g. It has been noticed that the tomato puree applied in thisfashion is further .distributed on the surface of the flat cake by thethereafter provided application of mozzarella or other garnishingingredients and in particular by the melting process and the thermalinteraction. In order to prevent a soiling by dripping tomato puree fromthe nozzles after the flat cake has been transported 11 d there is slid7 k a capturing cup 7 j under the nozzle ring 7 e. This capturing cup 7j is exchanged during the maintenance of the installation by a cleancup.

2. The selection and/or combining of the garnishing ingredients (tomatopuree, mozzarella, ham, salami, mushrooms, etc.) also for eachindividual order from the customer after the selection from an offerlist:

a. By having readily available pre-portioned garnishing ingredients inbubble bands 8 a and/or in dishes 18 and the corresponding meteringdevices 8, 9 and dispersion devices 10.

3. The unproblematic and uniform application of garnishing componentssuch as for example mozzarella, which are present in comminuted form butwhich have the tendency to stick:

a. Based on a metering and dispersing device 8 a (FIG. 6a) comprisingcooled container 19, wherein a downwardly flipped container 19 a with adownward opening and with the comminuted present garnishing product 19 eis disposed in the cooled container 19. A double grid 19 b is furnishedunder the opening of the flipped container 19 a, which double grid 19 bis moved by a known rattling mechanism 19 d in a direction perpendicularto the exit direction 19 f of the garnishing components 19 e. The twogrids or grates 19 f are disposed parallel to each other and at thedistance from each other, wherein the passage openings are tuned to thepiece size of the garnishing ingredients and can be different for thetwo grids or grates 19 b. The metering and dispersing device isfurnished under these rattling grids 19 b. The metering and dispersingdevice comprises a longitudinally shiftable 19 n perforated plate 19 k,which perforated plate 19 k is led between two parallel disposedperforated sheet metal pieces 19 g and 19 h. The bore holes of the upperperforated sheet metal piece 19 g are, relative to the bore holes of thelower perforated sheet metal piece, staggerred thereby at least by, thediameter of the perforation hole. The perforated plate 19 k is staggeredinitially into a position during the longitudinal motion 19 k with itsboreholes, where its bore holes coincide with the boreholes of the upperperforated sheet metal piece 19 g; in this position the garnishingpieces 19 e, which have fallen 19 f through the shaking grids 19 b, fallthrough the boreholes of the upper perforated sheet metal piece 19 f,through the boreholes of the upper perforated sheet metal piece 19 g andfill the boreholes of the perforated plate 19 k, which are thereuponshifted 19 n in the longitudinal direction. As soon as the boreholes ofthe perforated plate 19 k coincide with the boreholes of the perforatedsheet metal piece 19 h, then the garnishing particles 19 e can freelyfall downwardly onto the pizza 16 a. The number and the disposition ofthe boreholes in the perforated sheet metal pieces 19 g, 19 h and in theperforated plate 19 k are selected such that a dispersion as uniform aspossible and the surface covering is achieved. The invention does notexclude that the, perforated plate 19 k is disposed rotatable betweenthe perforated sheet metal pieces 19 g, 19 h and in each case is movedfurther in this direction around the staggered hole distance of theconcentrically disposed bore holes or is moved forward and backward. Thefilling of the boreholes of the perforated plate 19 k is favored by thesurrounding wall 19 q, which connects the rattling grids 19 b and whichdrags with its lower edge on the upper perforated sheet metal piece 19g; some continuously possibly sticking garnishing particles areindividualized by the motion 19 c of the rattling grids 19 b and of thewall 19 q.

4. The start of the proper baking phase of the pizza in the oven 13occurs already after about 20 seconds (from about 10 to 40 seconds)after the order placement by the customer:

a. This extremely short preparation time of the raw product is madepossible by the employment of the invention device for the preparationof the dough 5 (FIG. 2) and by the recited pre-portioning of the basecomponents and/or of the garnishing ingredients according to the presentinvention.

5. The discharge and delivery of the baked pizza within about 90 secondsafter ordering by the customer; this short time is made possible notonly by the extremely short preparation time of the raw product (about20 seconds, compare point 4) but in addition by the short baking time ofabout 70 seconds which is achieved by the following arrangementsaccording to the present invention:

a. By the pre-heating of the dough or, respectively, of the flat cakeimmediately after the exit 5 j out of the extruding nozzle 5 i on thepre-heated or, respectively, continuously heated transport plate 11,during the formation of the flat cake and during the application of thegarnishing ingredients,

b. By the baking of the flat cake and also of the applied garnishingingredients upon passing 16 b of the pre-heating tunnel 13 a, of thebaking oven 13,

c. By the baking of the pizza in an oven 13 made of a breathing porousceramic with a spatially relatively narrow limited baking zone 13 c,with the swivelled doors 13 e, 13 u, with a ceramic support plate 13 dfor the baking material, and with air spaces 13 f (hypocausts),

d. By the pre-heating of the insertion tunnel 13 a as well as thewithdrawal tunnel 13 b, which in each case are passed through and flowedthrough by the hot air of the baking zone 13 c during the insertion 16 bof the pizza or, respectively, during the withdrawal 16 c of the pizza,

e. And in particular by the direct contact of the pizza with the hot,porous support plate 13 d, without intermediate disposition of a bakingform or of a baking sheet metal or of a transport conveyor band, whichwould interfere with the heat transfer and also the escape of thehumidity from the dough mass.

6. The automatic repetition of the complete course of productioninitiated by each new order placed, also upon ordering of several likeor different kinds of pizza, without use of the prepared (deep frozenand/or pre-cooked) flat cakes and/or garnishing ingredients:

a. By the pre-proportioning of the dough base components and of thegarnishing ingredients, which in each case are taken as quantity units(bubble band, dish stack) from (possibly cooled) storage containers,

b. By the automatic opening and emptying of the portion packagecontaining the ingredients and the dispersion of the ingredients, or

c. By the lack of residues from production.

7. The automatic course and sequence of all phases of the productionwithout human interference as long as not one of the components has beenused:

a. By the automization and programming of the switching on and off ofthe operation, of the surveillance, of the cleaning end of thehygienization of the apparatus,

b. By the periodical exchange of components such as dispersion grate; 10b, feed lines 7 b, 7 d, 7 h, 7 i, catching cups 7 j and nozzles 7 e,wherein spoilable residues of food can contact the recited elements,

c. By the automatic cleaning of the apparatus for the production ofdough,

d. By the automatic collection of the packaging material (emptied bubblebands, emptied dishes).

It will be understood that each of the elements described above, or twoor more together, may also find a useful application in other types ofbaking system configurations and dough processing procedures differingfrom the types described above.

While the invention has been illustrated and described as embodied inthe context of a method and device for producing pizza, it is notintended to be limited to the details shown, since various modificationsand structural changes may be made without departing in any way from thespirit of the present invention.

Without further analysis, the foregoing will so fully reveal the gist ofthe present invention that others can, by applying current knowledge,readily adapt it for various applications without omitting featuresthat, from the standpoint of prior art, fairly constitute essentialcharacteristics of the generic or specific aspects of this invention.

What is claimed as new and desired to be protected by Letters Patent isset forth in the appended claims:
 1. A multiple station apparatus forautomated preparation of a pizza, the apparatus comprising: a. akneading device that prepares and extrudes a fresh dough from componentingredients, wherein the kneading device consists of two worms, includesa first and a second worm, each worm having a helical coil fixedlyconnected to a rotatable center axle, the coil and axle housed within anexterior casing, the first worm being perpendicularly aligned to thesecond worm, whereby the first and the second worms realize an effectivemixing, homogenizing, interspersing, densifying and extruding of thecomponent ingredients into the fresh dough; b. a shaping device thatshapes the fresh dough to a pre-determined dimension; c. at least onemetering device that apportions a pre-determined amount of at least onetopping for distribution on the fresh dough; d. an oven that bakes thepizza; and e. a transport device that transports the fresh dough throughthe multiple station apparatus.
 2. The apparatus of claim 1, furthercomprising a distribution device that applies the topping to the freshdough.
 3. The apparatus of claim 1, further comprising a metering andweighing device, a charge device and a mixing device that handles,apportions and prepares the component ingredients of the fresh doughprior to kneading.
 4. The apparatus of claim 1, wherein the first andthe second worms have independently controllable rotational speedsproviding control of individual fresh dough portion amounts dischargedfrom the kneading device.
 5. The apparatus of claim 1, wherein the coilof the first worm includes: a. a transport and densification regionwherein the coil is continuous about the center axle; and b. a kneadingregion where the coil is non-continuous about the center axle andincludes adjustable mixing blades.
 6. The apparatus of claim 1, whereinthe kneading device further comprises a transfer region located betweenthe first and the second worms, wherein the component ingredients aresubjected to a twisting and a torsion motion within the transfer region,the twisting and the torsion motion effecting homogenization and aninterspersion of the component ingredients under formation of airbubbles due to air pickup in the transfer region.
 7. The apparatus ofclaim 1, wherein a transfer region is located at a discharge end of thefirst worm, the transfer region being conically shaped and narrowinginto the second worm.
 8. The apparatus of claim 1, wherein the kneadingdevice is cleanly flushed and sterilized with hot air according to apre-programmed washing and sterilization cycle through an increase ofrotation speed and change of direction of rotation of the two worms. 9.The apparatus of claim 1, wherein the kneading device further comprisesa cutting device located at a discharge end of the second worm, thecutting device separating individual, compact fresh dough portionsallowing the fresh dough portions to fall freely onto the transportdevice below.
 10. The apparatus of claim 9, wherein the kneading devicefurther comprises a closure device at an input end of the first worm,the closure device and the cutting device enclosing the kneading deviceduring standstill of the first and the second worms.
 11. The apparatusof claim 1, wherein the transport device is heated to prevent the freshdough from sticking to the transport device.
 12. The apparatus of claim1, wherein the transport device is heated to provide rigidity to thefresh dough thereby preventing dough deformation during placement of thepizza in the oven.
 13. The apparatus of claim 1, wherein the transportdevice is heated to provide a pre-baking of the dough thereby shorteningbaking time in the oven.
 14. The apparatus of claim 1, wherein thetransport device serves as a support for the dough during dough shaping.15. The apparatus of claim 1, wherein the transport device serves as asupport for the dough during sliding and placement of the dough into theoven.
 16. The apparatus of claim 1, wherein the transport device forms acircular path within the apparatus.
 17. The apparatus of claim 1,wherein the transport device includes: a. a transport plate to supportthe fresh dough; and b. a transport mechanism that transports the plateand the fresh dough through the apparatus.
 18. The apparatus of claim17, wherein the transport device includes multiple transport platesfacilitating the automated preparation of multiple pizzas at a singlepoint in time.
 19. The apparatus of claim 18, wherein the oven includesmultiple baking zones facilitating the baking of multiple pizzas at asingle point in time.
 20. The apparatus of claim 1, wherein the shapingdevice includes a press having a cylinder that moves a disk to flattenthe fresh dough against the transport device.
 21. The apparatus of claim20, wherein the shaping device further comprises a ring in movablecommunication with the disk, the ring limiting an outer perimeterdimension of the dough when flattened by the disk while providing anintermediate space between the ring and the outer perimeter of the diskallowing the formation of a thicker upwardly projecting edge to an outerperimeter of the flattened dough, the thicker upwardly projecting edgeretaining the topping on the dough and preventing deformation of thedough during insertion into and removal from the oven.
 22. The apparatusof claim 1, wherein the metering device apportions and disperses tomatopulp, sauces or purees on the fresh dough and includes: a. a peristalticpump that meters and delivers a pre-determined volume of tomato pulp,sauce or puree; and b. at least one nozzle dispersing the tomato pulp,sauce, or puree on the fresh dough.
 23. The apparatus of claim 22,further comprising a feed line and a discharge line, wherein theperistaltic pump, the at least one nozzle, the feed line and thedischarge line form one single tubular piece allowing exchange of theone single tubular piece for cleaning of the metering device.
 24. Theapparatus of claim 23, wherein multiple nozzles are variably positionedover the dough providing uniform dispersion of the pre-determined volumeof tomato pulp, sauce or puree to the dough.
 25. The apparatus of claim24, further comprising a compressed air system having multiple airnozzles positioned over the dough, each air nozzle located in respectivecoordination with a nozzle dispersing tomato pulp, sauce or puree,whereby air passing through the air nozzles assists in providing uniformdispersion of the pre-determined volume of tomato pulp, sauce or pureeto the dough.
 26. The apparatus of claim 1, wherein the metering deviceapplies garnishing ingredients on the dough, the garnishing ingredientsbeing individually portioned by packaging in dishes, the dishes forminga stack in the metering device.
 27. The apparatus of claim 26, wherein abottom of a first dish forms a cover for a second dish locatedthereunder in the stack.
 28. The apparatus of claim 26, wherein themetering device includes: a. at least one magazine that stores the stackof dishes; b. a tilting station that releases the garnishing ingredientsfrom the dishes onto the dough; and c. a slider that mechanicallyretrieves the dishes from the magazine and transports the dishes to thetilting station.
 29. The apparatus of claim 28, wherein the sliderfurther transports the dishes to a storage container after thegarnishing ingredients are released by the tilting station.
 30. Theapparatus of claim 28, wherein the slider operates by a piston totransport the dishes from the magazine to the tilting station.
 31. Theapparatus of claim 28 further comprising a vibrating dispersing devicethat receives the garnishing ingredients from the tilting station andapplies the garnishing ingredients to the dough.
 32. The apparatus ofclaim 31, wherein the vibrating dispersing device further comprises asieve or grate to uniformly apply the garnishing ingredients onto thedough.
 33. The apparatus of claim 28, wherein the dishes are subdividedinto cells and further include a grate or sieve to uniformly distributethe garnishing ingredients onto the dough.
 34. The apparatus of claim 1,wherein the oven includes: a. a baking zone; b. an insertion openinghaving a door through which the pizza is inserted for baking; and c. aremoval opening having a door through which the pizza is removed afterbaking, wherein the oven, the baking zone and the doors are made of aporous vapor-permeable ceramic allowing an uptake of baking vapors andan air exchange during baking, whereby a baked pizza resembles thatbaked in a charcoal-fired oven.
 35. The apparatus of claim 34, whereinthe oven further includes a first heat tunnel located at the insertionopening and a second heat tunnel located at the removal opening, thefirst and the second heat tunnel preventing an air exchange in thebaking zone during pizza insertion into and removal from the bakingzone.
 36. The apparatus of claim 35, wherein the first and second heattunnels are heated by discharge heat from the baking zone.
 37. Theapparatus of claim 35, wherein air exchange in the baking zone isperformed by air preheated in at least one of the heat tunnels.
 38. Theapparatus of claim 34, wherein dimensions of the baking zone are limitedclosely to dimensions of the pizza to be baked in the baking zone.